BLAST FURNACE BURDEN

PERMEABILITY

oleh

Nick Standish,

October 2013
 In its simplest form, the making of iron in a
Blast Furnace is given by:

FeO + CO = Fe + CO2
 
This equation asserts that to make iron:

1. THERE MUST BE AN IRON OXIDE AS A REACTANT.

 
2. THE IRON OXIDE AND THE REDUCING GAS MUST
CONTACT (+) EACH OTHER PROPERLY.
  TO MAKE LOW COST HOT METAL TWO EXTRA
REQUIREMENTS MUST BE SATISFIED:

1. THE OXIDE MUST BE LOW COST AND HAVE:

- LOW LTB,
- SUPERIOR
REDUCIBILITY, and - HIGH Fe,
AND

 2. THE COKE MUST BE LOW COST AND HAVE:

. - HIGH CSR, and
- A LOW REACTIVITY
.

THAT MATCHES THE . OXIDE REDUCIBILITY.

PHYSICAL BLAST FURNACE
 CHEMICAL BLAST FURNACE

Fe2O3 Fe3O4 FeO Fe

O/Fe Ratio 1.5 1.33 1.0 0.0
O2 to be removed 0.17 0.33 1.0 0.0
CO level required @ 1000 oC,% 0.5 27.0 75.0 0.0
 RIST DIAGRAM
Every Blast Furnace Process Engineer must fully
comprehend all aspects of the Rist Diagram. And
every BF operator must know its basics.
 Sir Charles Goodeve, FRS at the BCURA Annual
Lecture in 1957 said:

“ At the high temperatures involved, the

energy of activation is never a restriction.
Metallurgical reactions should be able to
proceed at enormous speed, but, in fact,
they do not because the chemical
engineering has failed to mix the reactants
fast enough.”
 FLOW THROUGH PACKED BEDS
In 1952 Ergun showed that the pressure loss in packed beds consists of
two terms, namely:
DP = Viscous loss + Kinetic loss

In blast furnaces kinetic energy loss predominates, so there, Ergun

equation is:
DP = f L u2 r (1 – e)/fdp e3

Where: f - Friction factor (= 1.75).

L - Bed length/height.
u - Superficial velocity.
r - Fluid density.
dp - Harmonic mean particle size.
f - Particle shape (sphericity).
How fast does the gas go through
the blast furnace?
In the Blast Furnace it is not the gas velocity that is
important, but as noted earlier it is the contacting
between the gas and the solids, or:

FeO + CO = Fe + CO2
 AND THAT CONTACTING (+) MUST BE PROPER!
Proper means having an optimum permeability in
every volume element in the blast furnace.
And the only way to achieve this is to get
correct burden distribution –
THERE IS NO OTHER WAY!
 PERMEABILITY (Q)

Unlike in most textbooks my permeability uses Ergun equation, but focusses

on the packing and is defined as: .

The ability
of the packing to pass gas through it under standard conditions
of DP, A, L, f and r.

Where: K - Standard conditions of DP, A, L, f and r.

 - Geometric factor (0 – 1).
dp - Harmonic mean particle size.
f - Particle shape (sphericity)
e - bed porosity.
Sphericity and binary porosity
Bagian Density

0.7

0.6

Ukuran Tunggal
0.5 Bubuk

0.4
0.0 0.5 1.0
 Ternary systems porosity
In connection with their investigation of ternary porosities, K Ridgway and KJ
Tarbuck; Chem Process Eng, 49, (1968) 103, said:

“No theoretical or intuitive reasoning would predict the

trend of the isoporosity lines in these mixtures.”

I DID NOT AGREE!

POROSITIES in 2, 3 and 4 SIZE SYSTEMS
 standish porosity - google
• About 524,000 results (0.35 seconds) 
• Aibing Yu « School of Materials Science and Engineering – UNSW
• A.B. Yu and N. Standish, “Estimation of the porosity of particle mixtures by a linear-mixture packing model”, Industrial & Engineering Chemistry Research,  ...
• Limitation of the simplex-centroid design for the porosity calculation ...
• www.sciencedirect.com/science/article/pii/0032591087801262
• Limitation of the simplex-centroid design for the porosity calculation of ternary mixtures. N. Standish,; A.B. Yu. Department of Metallurgy and Materials  ...
• The Porosity of Particulate Mixtures Experimental measurements are ...
• www.sciencedirect.com/science/article/pii/.../pdf?md5...pid=1-s2.0...
• by N Standish - 1979 - Cited by 38 - Related articles Powder Technology, 22 (1979) 121- 125. 0 ELsevier Sequoia S-A., Lausanne -Printed iu the Netherlands. The  Porosity of Particulate Mixtures.
N. STANDISH.
• River Flow 2012 - Page 630 - Google Books Result
• books.google.com/books?isbn=0415621291
• Rafael Murillo Muñoz - 2012 - Science An attempt to fill this knowledge gap was made by Frings (2011), by using the theoretical porosity model of Yu and Standish (1991), as adapted by Yu and  ...
• Limitation of proposed mathematical models for the porosity ...
• pubs.acs.org/doi/pdf/10.1021/ie00021a043 by AB Yu N. Standish.. - 1993 - Cited by 16 - Related articles
• NUMERICAL ANALYSIS OF POROSITY OF ... - ASCE Library
• ascelibrary.org/doi/pdf/10.1061/40932(246)121
• by W HUANG - 2007 - Related articles predict the porosity and permeability of multi-component mixtures (Standish, 1979). Researchers have studied the packing of binary mixtures experimentally
and.
• Porous ceramic membranes proefschrift - Universiteit Twente
• doc.utwente.nl/9215/2/t0000015.pdf
• by PM Biesheuvel - 2000 - Cited by 4 - Related articles Yu, A.B., and N. Standish, “Porosity calculation of multicomponent mixtures of spherical particles,” Powder. Tech., 52, 233-241 (1987).
• Permeability analysis in bisized porous media: Wall effect between ...
• https://bibliotecadigital.ipb.pt/bitstream/10198/463/.../Dias-JHydrology.p...
• by RP Dias - 2008 - Cited by 13 - Related articles Binary packing porosity has been extensively investigated in numerous works (Yu andStandish, 1988) and it has been observed that granular  ...
• Particulate Binary Mixtures - Biblioteca Digital do IPB - Instituto ...
• bibliotecadigital.ipb.pt/bitstream/10198/7039/1/2004-17.pdf
• by RP Dias - 2004 - Cited by 31 - Related articles GENERAL RESEARCH. Particulate Binary Mixtures: Dependence of Packing Porosity on.....  Yu and Standish;17 7.
• Porosity and hydraulic resistance of a bidisperse mixture - Springer
• link.springer.com/article/10.1007%2Fs10891-007-0089-6
• by JG Dueck - 2007 - Related articles Jul 1, 2007 - A. B. Yu and N. Standish, Porosity calculations of multicomponent mixtures of spherical particles, Powder Technology, 52, 233–241 (1987).
• Predicting Packing Characteristics of Particles of Arbitrary Shapes†
• www.kona.or.jp/search/22_082.pdfby M Gan - Cited by 32 - Related articles Aug 26, 2004 - Yu, A.B. and N. Standish: “Porosity calculation of multi- component mixtures of particles”, Powder Technol.,
52. (1987), 233-
• 12. Classification of Grain Size Distribution Curves of Bed Material and ... www.dpri.kyoto-u.ac.jp/dat/nenpo/no50/ronbunB/a50b0p64.pdf by M SULAIMAN - Cited by 4 - Related articles
The porosity of sediment mixtures depends on the grain size distribution (Standish and. Borger, 1979; Tsutsumi et al., 2006). If the porosity is related to the grain  ...
• 13. Image analysis of packed beds of spherical particles of ... - Yelshin.net
• www.yelshin.net/downloads/ID-930.pdf by M Mota - 1999 - Cited by 35 - Related articles that the region of minimal porosity for dense packing is broader than in the case of binary mixtures (Fig. 4).
According to Yu and Standish [11] the maximal….
• 14. Graded membrane supports produced by centrifugal casting of a ...
• albus.fenk.wur.nl/~biesheuvel/CES_CCSD.pdf by PM Biesheuvela - 2001 - Cited by 49 - Related articles porosity  equations while we refer to Yu and Standish (1987) for expressions for the  ...

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PERMEABILITIES in 3 and 4 SIZE SYSTEMS
WHAT ABOUT SEGREGATION?
 MORE SEGREGATION!

Segregation
in a heap
stacked
from two
bins having
a different
in-bin
segregation.
 SEGREGATION RULE
Size difference is by far the
worst for giving segregation.
Others are differences in
shape and density, but they
are minor. Therefore,

ELIMINATE DIFFERENCE IN PARTICLE

SIZE OR RELATIVE MOTION BETWEEN
PARTICLES AND YOU ELIMINATE
SEGREGATION!
 WHY ARE WE INTERESTED IN SEGREGATION?
With bells, rolling of burden is inevitable. This leads
to segregation and permeability problem resulting in
channelling, cross flow etc of gas and all this
means inefficient operation and high costs.

To solve it Germans installed movable

armour and the Japanese added
bells instead. But Nothing helped!

Then Bell-Less Top was developed by

Paul Wurth Company of Luxembourg.
 THE BELL-LESS TOP
Unfortunately the Paul Wurth
(PW) bell-less top (BLT) did not
solve the segregation. P

Left is Redcar’s

14 m BF PW BLT
BLT chute samples
showing odd
results, namely segregation of the
bulk sample bulk sample and chute
 MORE BLT PROBLEMS
Schwelgern No 1 BF, also a 14m furnace, showed
unsymmetrical SL geometry due to 180o change
of the stream impacting the chute.
 CENTRAL BLT - A SOLUTION?
The first full size investigation of central BLT concept
was done in Dillinger Hütte by Lothar Kreutz as part
of his Dr-Ing thesis supervised
by Prof HW Gudenau and me.
Mündliche Prüfung Dr-Ing RWTH
Aachen 1988
Dr-Ing Michael Peters
 3rd GENERATION PW BLT
Then PW produced a new design of central BLT, with
top hopper rotating to solve segregation. It did not solve
it!

I got the job of fixing it INCLUDING

guaranteeing a ±10 % max deviation of mean size
at the tip of the rotating chute from start to
finish of discharge.
The first 3G PW Central BLT was installed in
Anshan No 9 BF in 1990. It soon followed by Solmer, Italsider
and BHP Port Kembla No 6 BF in 1992.

Then I came to Cilegon to help Krakatau Steel!

 THE SOLUTION TO PW 3G CENTRAL BLT
SEGREGATION
There are two problems that
cause discharge segregation
from any hopper, namely:
1. In-bin segregation,
2. Bin flow pattern.
For most practical purposes Under
both are solved by mass flow.
Because of height limitations
my solution was use an insert.
 ORE-COKE INTERFACES

In a blast furnace ore and coke are

layered on top of each other. When
ore is placed on top of coke the
smaller and heavier ore particles
penetrate into the coke forming a
stalactite-like interface.

The sample on the right is an actual

ore-on-coke layer taken from a SL of
a real 3,000 cum BF showing a part
of an
 INTERFACE SIGNIFICANCE
In the permeability equation

the term y is called the

geometric factor. Its value is
0.0 when the passage for the gas
is completely blocked and 1.0 when it is completely
open. For other cases it is inbetween.
The graph above shows about 20 Pa/cm for the whole
ore layer and 40 Pa/cm for the interface making y ≈ 0.75
for this sample. The results show it is the -9 mm
fraction that formed the interface.
 BURDEN PERMEABILITY

It is important to measure the real burden

permeability because the real burden layers
are so much different from laboratory burdens.
 EXTENSION
The only way to achieve correct
permeability is to get correct
burden distribution. THERE IS NO
OTHER WAY! And use a central BLT!
By the way, the results of our investigations
have been extended to actual practice. Below is burden
distribution that will be adopted by Krakatau Posco.
Does KS-CERI BF
have such burdening
in their contract?
I could not find it!
 STANDISH DIAGRAMS
At the McMaster Symposium in
1980 on BF Coke I presented
simple permeability diagrams
dubbed Standish Diagrams.
They did not catch on widely!

An example given, plotted

degradation of Hatano’s alkali
containing coke and Warner’s tuyere
sampled coke (see left) suggesting the cause for
the tuyere coke was also alkalis.
WE DON’T LIKE ALKALIS!
 KESIMPULAN

BAHAN BAKU PRIME PRIME 2nd 2nd

BURDEN
DISTRIBUTION VERY MEDIOCRE VERY MEDIOCRE
KNOWLEDGE HIGH HIGH

COST HOT EXTRA NOT LOW LOW BANKRUT !

METAL LOW
TERIMA KASIH
 APAKAH TERJADI DI DALAM BF?
Bahan baku masuk secara layer. OCOCOC . . . . Dari
bawah ada hot, reducing gas. Biasa ≤950 Co sinter
dan coke hanya dipanaskan –tidak ada reaksi kimia.
Sekitar 1000Co ada “indirect reduction” yaitu:
FeO +CO = Fe + CO2 ΔHo = -17MJ/kgmol
Di atas 1000 Co ada “direct reduction”
FeO +C = Fe + CO ΔHo = +165MJ/kgmol

(FeO +CO = Fe + CO2 dan CO2 + C = 2 CO) +172MJ/kgmol